Concrete Repair According to the new European Standard EN 1504

Prof. Dr.-Ing. M. Raupach,

RWTH Aachen, ibac

ABSTRACT: Great effort has been made to work out a European Standard on protection and repair of concrete
structures. After more than ten years of intensive discussions within different working groups the series of standards is
now more or less finalised. Actually the European Countries are preparing to replace the existing national standards
and recommendations by the new European Standard EN 1504. It can be assumed that this standard will have a
significant impact also to the Non-European countries.

INTRODUCTION

Repair and restoration of concrete structures has

become an important market. As an example the costs
for the maintenance of bridges are higher than 1 billion $
per year. The total costs for maintenance of all types of
buildings can be assumed to be higher than about 20
billion $ per year. A significant part of this costs are
spent on repair and protection of concrete structures.
On the contrary to the amount of work spent on building
new structures, the market of repair and protection has
grown considerably as the age of the existing
infrastructure is increasing. The extensive development
of new methods and materials for the repair and
protection of concrete structures has led to the need of
standards for such works and products.
Table 1 shows the structure of the new EN 1504,
consisting of 10 main standards and about 65 standards
for test methods. As shown in table 1 the series of
standards is focused on parts 2 to 7, which are the basis
for CE marking of the different products and systems to
be used for protection and repair of concrete structures.
However, part 9 of EN 1504 is not less important,
describing the principles for the use of the products,
which will be explained in the following sections. Part 1
gives definitions, part 8 regulates the quality control of
the products and part 10 gives a general guideline for
site application and quality control of the works. To
allow CE marking of the products about 65 standards
describing test methods for the different properties of the
products had to be prepared. These standards ensure
that testing of the products will be according to the same
standards for all products for protection and repair of
concrete structures used in Europe.

Table 1:

Structure of EN 1504
Futher test
methods

EN 1504-1 Definitions

EN 1504-9
Principles for the
use of the products

EN 1504-2 to 7:
Products
- surface protection
- repair mortars
- bonding materials

EN 1504-10
Site application
and quality control
of the works

- injection materials
- anchoring products
- coatings for steel

Test methods
(about 65
standards)
EN 13 396
(chloride ingress)
.
.
.
EN 14 497
(filtration stability)

EN 1504-8 Quality control of the products

PHASES OF REPAIR PROJECTS

The phases of repair projects follow a logical sequence,

which is dominated by engineering aspects. Table 2
gives a general scheme according to figure B1 within
annex B of EN 1504-9. This figure shows the wellknown elements as assessment, planning, design and
quality control. However, the systematics of general
planning is quite new related to the actually existing
recommendations and standards. It consists of a
hierarchy of levels, namely options, principles and
methods, which are described in more detail in section
4.

Table 2: The phases of repair projects

Management
of the Structure

General
Planning

Design of
Repair Work

Options
Principles
Methods

Definitions of the
intended use of
products

Process of
Assessment

Acceptance of
Repair Work

Repair Work

Basic considerations and actions

Conditions and
history of
structure

Defects and
their classification and
causes

Requirements
- substrate
- products
- work
- specifications
- drawings

Documentation
Commissions
for maintenance

Choice and use

of products and
equipment

Acceptance
testing

Tests of quality
control

Remedial works

Health and safety

Documentation

Parts of the EN 1504 series and clauses of EN 1504-9

Clause 8 of
EN 1504-9

4.3 of
EN 1504-9

Clauses 5
and 6 of
EN 1504-9

EN 1504-2 to
EN 1504-7 and
clause 7 and
annex A of
EN 1504-9

Clause 9 of
EN 1504-9 and
ENV 1504-10

PROCESS OF ASSESSMENT

Table 3 shows common causes of defects according to

figure 1 of EN 1504-9. With respect to later planning of
repair, generally it should be distinguished between
defects in concrete and defects caused by reinforcement
corrosion. The purpose of the main assessment is
to identify the cause or causes of defects
to establish the extent of defects

to establish where the defects can be expected to

spread to parts of the structure, that are at present
unaffected
to assess the effect of defects on structural safety
and
to identify all locations, where protection or repair
may be needed.
More details on requirements for assessment are given in
EN 1504-9.

Table 3: Common causes of defects

Defects in Concrete

Mechanical

Chemical

Reinforcement Corrosion

Physical
Carbonation

Impact
Overload
Movement
(e.g. settlement)
Explosion
Vibration

Alkali-aggregate
reaction

Freeze/thaw

Aggressive agents
e.g. sulphates,soft
water, salts

Salt
crystallization

Biological activities

Erosion

Corrosive
contaminants

Stray currents

Thermal

Shrinkage
Wear

At mixing

From external
environment

Sodium Chloride

Sodium Chloride

Calcium Chloride

Other
contaminants

Figure 1: Example for a damage of the concrete

Figure 2: Example for reinforcement corrosion caused by

carbonation of the concrete

Figure 3: Example for reinforcement corrosion caused by

chloride ingress

account in deciding the appropriate action to meet the

future requirements for the life of the structures:
(a) Do nothing for a certain time
(b) Re-analysis of structural capacity, possibly leading
to downgrading of the function of the concrete
structure.
(c) Prevention or reduction of further deterioration,
without improvement of the concrete structure.
(d) Improvement, strengthening or refurbishment of all
or parts of the concrete structure.
(e) Reconstruction of part or all of the concrete
structure and
(f) Demolition of all or part of the concrete structure.
For protection and repair, different principles have been
defined, separately for repair and protection of damages
to the concrete and damages induced by reinforcement
corrosion. Tables 4 and 5 show the 6 principles for
protection and repair of concrete and the 5 principles to
prevent damages due to reinforcement corrosion
respectively. Theses principles are based on the RILEM
Technical Recommendation 124-SRC Strategies for
repair of concrete structures damaged by steel
corrosion. To protect or repair a concrete structure
according to the principles different methods are
available. Figures 8-15 in annex A of this paper show
the methods and short descriptions for the 11 principles.
Altogether 37 methods are described within EN 15049. Not all of them are covered by the EN 1504 series,
but by other standards, and some of them are actually
not standardised, but expected to be regulated in future.
The system of options, principles and methods is the
basis for the selection of products by the designer. The
process of planning and selection of products is
described within the next section.
Table 4: Principles for repair and protection for damages of the
concrete
Principle No.

OPTIONS, PRINCIPLES AND METHODS

FOR PROTECTION AND REPAIR

As already mentioned, the rules for the use of products

and systems for protection and repair of concrete
structures is based on a hierarchy of different levels,
namely options, principles and methods. According to
EN 1504-9 the following options shall be taken into

Principle and its definition

Principle 1 [PI]

Protection against ingress

Principle 2 [MC]

Moisture Control

Principle 3 [CR]

Concrete Restoration

Principle 4 [SS]

Structural Strengthening

Principle 5 [PR]

Physical resistance

Principle 6 [RC]

Resistance to chemicals

Table 5: Principles for protection against reinforcement

corrosion
Principle No.

Principle and its definition

Principle 7 [RP]

Preserving or Restoring Passivity

Principle 8 [IR]

Increasing Resistivity

Principle 9 [CC]

Cathodic Control

Principle 10 [CP]

Cathodic Protection

Principle 11 [CA]

Control of Anodic areas

Figure 6: Example for applying mortar by hand according to

method 3.1 (Table 10)

Figure 4: Example for surface coating according to method 1.2

(Table 8), 2.2 (Table 9), 6.1 (Table 12) or 8.1 (Table 14)

Figure 7: Example for recasting with concrete according to

method 3.2 (Table 10)

Figure 5: Example for hydrophobic impregnation according to

method 2.1 (Table 9)

Figure 8: Example for plate bonding according to method 4.3

(Table 11)

characteristics relevant for the selected repair methods.

EN 1504-2 to 7 contain the performance characteristics
of the products together with the corresponding test
methods. In this way the products are selected individually for the demands of the special case of repair or
protection of a concrete structure. As a result, the
products are described by a list of required performance
characteristics instead of simple classes, resulting in a
high level of flexibility, but also responsibility of the
designer.
Finally inspection and maintenance requirements shall be
defined by the designer.
Table 6: Systematics of planning according to EN 1504-9
Assessment of the status of the structure (defects ...)

Figure 9: Example for injection of cracks according to method

4.5 (Table 11)

Elaboration of the repair strategy (do nothing, repair, ..., demolition)

Definition of the repair principles (e.g. protection against ingress ...)

Selection of the repair method (e. g. impregnation ...)

Definition of the repair materials (strength, modulus, adhesion, etc.)

Definition of inspection and maintance requirements

PLANNING AND SELECTION OF

PRODUCTS

Table 6 shows the systematics of planning according to

EN 1504-9. As already shown in table 2, the planning
starts with the assessment of the status of the structure.
The following points are selection of options (repair
strategy), repair principles and repair method, as defined
in the previous section. Based on this selection scheme
the repair materials can be chosen. EN 1504-9 defines
performance characteristics for every repair method,
separately for all intended uses and for certain intended
uses. The designer selects the performance
characteristics based on the requirements of the special
repair project and the selected repair methods. Table 7
gives 3 examples of certain cases, with the performance

CONCLUSIONS AND OUTLOOK

A new European standard on protection and repair of

concrete structures has been worked out, based on the
actual state of knowledge regarding the properties of the
products, the principles for the use of the products,
application and quality control. Parts 2 to 7 regulate the
performance of the products and systems for protection
and repair of concrete structures with respect to CE
marking. The use of the products is based on a logical
sequence consisting of options (repair strategies), repair
principles and repair methods, which are listed in tables
in part 9 of EN 1504. This scheme ensures that suitable
products are selected based on the requirements of the
practical case. It is expected that this new series of standards will replace the existing national standards in
Europe within the next 2 or 3 years and that it will also
have significant impact for other countries.

Table 7: Examples of the application of the classification system in 3 individual cases according to EN 1504-2
No.
Test methods
according
defined in
to Table 1

Example 1 Example 2 Example 3

1.3/2.2 1.3/5.1/6.1 1.3/5.1

Performance characteristics

EN 12617-1

Linear shrinkage

EN12190

Compressive strength

EN ISO 5470-1

Abrasion resistance

EN1062-6

Permeability to CO 2

EN ISO 7783-2

Permeability to water vapour

EN1062-3

Capillary absorption and permeability to water

Adhesion after thermal compatibility

EN 13687-1

Freeze-thaw cycling with de-icing salt immersion

EN 13687-2

Thunder shower cycling (thermal shock)

EN 106211:2002

4.1: Aging 7 days at 70 C

12

EN 13529

Resistance to severe chemical attack

13

EN 1062-7

Crack bridging ability

14

EN ISO 6272-1

Impact resistance

15

EN 1542

Adhesion by Pull-off test

18

EN 13036-4

Slip/Skid resistance

20

EN 106211:2002

4.2 Behaviour after artificial weathering

EXAMPLE 1

Coating system for exposed surfaces, not mechanically or chemically loaded, without de-icing salt influence
acc. to the principles 1 (IP) and 2 (MC), see Table 1, 1.3 (C) and 2.2 (C).

EXAMPLE 2

Coating system for interior surfaces, mechanically and chemically loaded, in acc. to the principles 1 (IP),
5 (PR) and 6 (RC), see Table 1, 1.3 (C), 5.1 (C) and 6.1 (C).

EXAMPLE 3

Crack bridging coating system for exposed surfaces mechanically and low chemically loaded, with de-icing
salt influence in acc. to the principles 1 (IP) and 5 (PR), see Table 1, 1.3 (C) and 5.1 (C).

7
[1]

[2]

[3]

LITERATURE
EN 1504-1 1998-01-00. Products and systems for the protection and repair of concrete
structures - Definitions, requirements, quality
control and evaluation of conformity - Part 1:
Definitions
EN 1504-2 2004-10-00. Products and systems for the protection and repair of concrete
structures - Definitions, requirements, quality
control and evaluation of conformity - Part 2:
Surface protection systems for concrete
DIN EN 1504-3 2001-06-00 Products and
systems for the protection and repair of
concrete structures - Definitions, requirements,

[4]

[5]

[6]

quality control and evaluation of conformity Part 3: Structural and non-structural repair;
German
version
prEN 1504-3:2001
(WITHDRAWN in October 2004)
EN 1504-4 2004-11-00. Products and systems for the protection and repair of concrete
structures - Definitions, requirements, quality
control and evaluation of conformity - Part 4:
Structural bonding
prEN 1504-5 2004-04-00. Products and systems for the protection and repair of concrete
structures - Definitions, requirements, quality
control and evaluation of conformity - Part 5:
Concrete injection
prEN 1504-6 2004-05-00. Products and systems for the protection and repair of concrete

[7]

[8]

structures - Definitions, requirements, quality

control and evaluation of conformity - Part 6:
Anchoring of reinforcing steel bar
DIN EN 1504-7 2005-01-00 Products and
systems for the protection and repair of
concrete structures - Definitions, requirements,
quality control and evaluation of conformity Part 7: Reinforcement corrosion protection;
German version prEN 1504-7:2004
EN 1504-8 2004-11-00. Products and systems for the protection and repair of concrete
structures - Definitions, requirements, quality
control and evaluation of conformity - Part 8:
Quality control and evaluation of conformity

[9]

[10]

ENV 1504-9 1997-07-00. Products and systems for the protection and repair of concrete
structures - Definitions, requirements, quality
control and evaluation of conformity - Part 9:
General principles for the use of products and
systems
EN 1504-10 2003-12-00. Products and systems for the protection and repair of concrete
structures - Definitions, Requirements, Quality
control and evaluation of conformity - Part 10:
Site application of products and systems and
quality control of the works

ANNEX A
Tables 8-15:
Table 8: Principle no. 1
Principle No.

Principle and its definition

Principle 1 [PI]

Protection against ingress

Reducing or preventing the
ingress of adverse agents,
e.g. water, other liquids,
vapour, gas, chemicals and
biological agents.

Methods based on the principle

1.1 Impregnation
Applying liquid products which
penetrate the concrete and block
the pore system.
1.2 Surface coating with and without
crack bridging ability
1.3
1.4
1.5
1.6
1.7

1)
2)

Locally bandaged cracks 1)

Filling cracks
Transferring cracks into joints
Erecting external panels 1) 2)
Applying membranes 1)

1)

These methods may make use of products and systems not covered by the EN 1504 series
Inclusion of methods in this Prestandard does not imply their approval

Table 9: Principle no. 2

Principle No.

Principle 2 [MC]

Principle and its definition

Methods based on the principle

Moisture Control
Adjusting and maintaining
the moisture content in
the concrete within a
specified range of values.

2.1 Hydrophobic impregnation

2.2 Surface coating
2.3 Sheltering or overcladding 1) 2)
2.4 Electrochemical treatment 1) 2)
Applying a potential difference
across parts of the concrete to
assist or resist the passage of
water through the concrete.
(Not for reinforced concrete
without assessment of the
risk of inducing corrosion).

1) These
2)

methods may make use of products and systems not covered by the EN 1504 series
Inclusion of methods in this Prestandard does not imply their approval

Table 10: Principle no. 3

Principle No.

Principle and its definition

Methods based on the principle

Principle 3 [CR] Concrete Restoration

Restoring the original concrete
of an element of the structure
to the originally specified shape
and function.

3.1 Applying mortar by hand

3.2 Recasting with concrete
3.3 Spraying concrete or mortar
3.4 Replacing elements

Restoring the concrete structure

by replacing part of it.

Table 11: Principle no. 4

Principle No.
Principle 4 [SS]

Principle and its

definition

Methods based on the principle

Structural Strengthening
Increasing or restoring the
structural load bearing
capacity of an element
of the concrete structure.

4.1 Adding or replacing embedded or

external reinforcing steel bars
4.2 Installing bonded rebars in
preformed or drilled holes
in the concrete
4.3 Plate bonding
4.4 Adding mortar or concrete
4.5 Injecting cracks, voids or
interstices
4.6 Filling cracks, voids or interstices
4.7 Prestressing - (post tensioning) 1)

1) These

methods may make use of products and systems not covered by the EN 1504 series

Table 12: Principle no. 5-6

Principle No.

Principle and its definition

Methods based on the principle

Principle 5 [PR] Physical resistance

Increasing resistance to
physical or mechanical attack.

5 . 1 Overlays or coatings
5 . 2 Impregnation

Principle 6 [RC] Resistance to chemicals

Increasing resistance of the
concrete surface to deteriorations by chemical attack.

6 . 1 Overlays or coatings
6 . 2 Impregnations

Table 13: Principle no. 7

Principle No.
Principle 7 [RP]

Principle and its

definition

Some examples of methods based

on the principle

Preserving or Restoring
Passivity

7.1 Increasing cover to reinforcement

with additional cementitious
mortar or concrete

Creating chemical conditions in which the surface

of the reinforcement is
maintained in or is
returned to a passive
condition.

7.2 Replacing contaminated or

carbonated concrete
7.3 Electrochemical realkalisation of
carbonated concrete 1 )
7.4 Realkalisation of carbonated
concrete by diffusion
7.5 Electrochemical chloride
extraction 1)

1)

These methods may make use of products and systems not covered by the EN 1504 series

Table 14: Principle no. 8-9

Principle No.
Principle 8 [IR]

Principle and its

definition
Increasing Resistivity
Increasing the electrical
resistivity of the concrete.

Principle 9 [CC]

Cathodic Control
Creating conditions in
which potentially
cathodic areas of
reinforcement are
unable to drive an
anodic reaction.

2)

Some examples of methods based

on the principle
8.1 Limiting moisture content
by surface treatments,
coatings or sheltering
9.1 Limiting oxygen content
(at the cathode) by
saturation or surface
coating 2)

Inclusion of methods in this Prestandard does not imply their approval

Table 15: Principle no. 10-11

Principle No.

Principle and its

definition

Some examples of methods

based on the principle

Principle 10 [CP]

Cathodic Protection

10.1 Applying electrical potential 1)

Principle 11 [CA]

Control of Anodic areas

11.1 Painting reinforcement with

coatings containing active
pigments

Creating conditions in
which potentially
anodic areas of
reinforcement are
unable to take part
in the corrosion
reaction

11.2 Painting reinforcement with

barrier coatings
11.3 Applying inhibitors to the
concrete 1) 2)

1)

These methods may make use of products and systems not covered by the EN 1504 series

2)

Inclusion of methods in this Prestandard does not imply their approval